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  • Posted on 4th January 2023 in the categories: Automotive Industry, Injection Moulding

    Can Injection Moulding Solve the Electrification Challenges?


    The drastic growth in electrification in recent years highlights how there is a cleaner, more efficient way to power vehicles globally. Projected growth for the industry is said to be at a compound annual rate of almost 40%. By 2025, that’s almost 2,000,000 electric vehicles.

    The driving force behind the rapid development of electric vehicles consists of two key factors:

    • Government legislation
    • Environmental factors

    While OEM’s globally welcome the switch to electrification, it doesn’t come without its challenges. The main challenges to overcome revolve around the battery:

    • Making the battery lighter
    • Protecting the battery from harsh elements and impact
    • Ensuring the battery is able to power the vehicle for longer journeys

    In order to find better solutions for the above, material innovation is going to be key once the leap from prototyping and low-volume production to mass production is fully facilitated.

    The battery carrier

    The battery carrier in electric vehicles is vital for successful thermal management. The chemical changes that occur inside the battery have extreme consequences. Therefore, it’s essential the battery carrier keeps the battery from overheating.

    In addition, charging also proves a problem. The more time spent fully charged, the faster internal resistance builds up and similar issues can service. Over time, this will then cause the battery to become useless. Therefore, placing an emphasis on how thermal management is key.

    If damaged, EV batteries can give off toxic gases. Therefore, the carrier needs to be able to protect the battery extensively to avoid water pollution and depletion, among other things. Manufacturers have placed a priority on the battery carrier, ensuring it offers a protective structure to stop impact while also allowing for improved thermal management.

    Injection moulding supporting the switch to electrification

    Injection moulding offers design flexibility, meaning the more complex requirements of EV’s and their battery carriers can be easily accommodated. Industry experts have noted that innovations in materials and their properties are going to be key in developing an effective solution got battery protection.

    Plastics are a strong contender for this, offering an ideal option for delivering lightweight components that will, ultimately, make vehicles cleaner. Goudsmit UK offer cost-effective, end-to-end service for manufacturing polymeric materials. From assessing your design methodology for production issues to guidance with material selection and advice on your production options, our aim is to minimise any quality related, as well as mechanical and engineering challenges.

    In today’s marketplace, there is an array of polymers available. However, most polymers Goudsmit UK use are standards such as Nylons, ABS, LOPE, HIPS and Acetyl. More exotic polymers are available, and we can mould these without issue.

    As well as multi-cavity moulding for individual components, Goudsmit UK have a range of both vertical and horizontal machines which we run for insert moulding and two shot components. Inserts are typically machined, or stamped components manufactured by us and then over moulded with a polymer. We also twin shot mould dissimilar polymers such as a structural part over moulded with a rubber material, for example in seals or castor wheels. Over moulding is an extremely flexible manufacturing process which provides fantastic results.

    Goudsmit UK

    As manufacturers continue to move forward with mass production of electric vehicles, thermal management, lightweight and battery protection appear to be the key challenges that they need to overcome. In which manufacturers have started to look at injection moulding to overcome these challenges.

    Our specialisation is in the industrialisation of your component to ensure when it’s moulded that it’s dimensionally and visually right. We offer a wide range of post moulding options and can assemble multiple components to create your final product. Our extensive experience with part assembly, finishing and tooling for diverse applications ensures your parts meet the right tolerances and deliver the high-quality look and performance you need.

    For more information visit our polymer engineering webpage or download our products and services brochure.

    Contact us on +44 (0) 2890 271 001 or at info@goudsmit.co.uk

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